Insulated modular roof system

ABSTRACT

In one aspect there is provided an insulated modular roof system for a roof structure. The system comprises a plurality of modular panels suitable for installation onto the roof structure and a water-proof membrane. Each of the modular panels comprises a first planar member, an insulating layer covering substantially all of the first planar member and a plurality of lateral edges. Each of the plurality of lateral edges provides either a step-like configuration or a reverse step-like configuration. When installed on the roof structure, the plurality of modular panels are positionable so as to place the plurality of lateral edges of any two adjacent modular panels in a generally overlapping arrangement.

FIELD OF THE INVENTION

This invention relates to roofing systems, in particular insulatedmodular roofing systems.

BACKGROUND OF THE INVENTION

The background information discussed below is presented to betterillustrate the novelty and usefulness of the present invention. Thisbackground information is not admitted prior art.

Various roofing systems are known both for flat and sloped roofs toinsulate and waterproof the roof. On flat roofs the most common roofingsystem for waterproofing is a built up laminar structure comprising aplurality of felt layers with each layer or series of layers over-laidwith a hot bituminous (tar) composition to bind the felt to the roof. Alayer of gravel tops off the structure. However, this is a very labourintensive process and requires onsite machines and equipment (e.g. toprovide the hot tar).

In recent years, as the advantages of applying insulation on theexterior as opposed to the interior of the roof deck have become known,the built up roof structure has been applied over insulation materials,typically sheets of insulation material. This created new problems asthe insulating materials had poor mechanical properties, needed to befastened to the roof deck, are subject to degradation by UV radiationand absorbed moisture. In addition such built up roof systems are verylabour intensive making them less economical.

Numerous attempts have been made unsuccessfully to solve one or more ofthese problems. For example, U.S. Pat. No. 6,418,687 is directed forretro-fitting roofs, is field applied and non-modular. In particular,the foamed in place insulation described in this patent is designed tobe applied over a roof deck or existing roof substrate and a rubbermembrane is then glued over top of the sprayed insulation. Although thisaddresses some of the problems, a foamed-in place roofing installationis still very labour intensive to apply and requires spray foamingequipment on-site. Furthermore, when one spray-foams a large surfacearea there are often ripples, localized hills and valleys and otherimperfections that are formed and which translate into correspondingripples, hills, valleys and imperfections in the overlying rubbermembrane. These imperfects can then trap water or other precipitation inlocalized areas, preventing desired run-off, and ultimately resulting inponding and of such standing water seeping through cracks in the rubbermembrane.

Additionally, even on roofs that are classified as being “flat” it maydesirable to have a slight roof slope for water to run off. A typicalminimum roof slope is 1% (⅛″ per 1′). However, minimum slope for a“flat” roof is often set by building code to 2%. However, even for anexperienced and skilled spray-foam application worker, it is difficultto create a flat non-ponding surface using an on-site, foamed-in placeinsulation method. Moreover, it is very difficult, if not impossible, tocreate a slightly sloped roofing surface (from one side of the roof toanother) using such an on-site, foamed-in place insulation method;especially in new construction wherein there is no pre-existing,pre-sloped roof deck. In such cases, the system and method of U.S. Pat.No. 6,418,687 will simply not work.

Therefore, what is needed is a modular roofing system which can beapplied in new buildings, reduces on-site installation time, does notrequire a pre-existing, pre-sloped roof deck, does not require (orreduces the need for) on-site spay-foaming equipment, can be installedby unskilled laborers and can provide for an overall slope to theresulting roof structure.

SUMMARY OF THE INVENTION

In one aspect there is provided an insulated modular roof system for aroof structure. The system comprises a plurality of modular panelssuitable for installation onto the roof structure and a water-proofmembrane. In this aspect, each of the modular panels comprises a firstplanar member, an insulating layer covering substantially all of thefirst planar member and a plurality of lateral edges. Each of theplurality of lateral edges provides either a step-like configuration ora reverse step-like configuration. When installed on the roof structure,the plurality of modular panels are positionable so as to place theplurality of lateral edges of any two adjacent modular panels in agenerally overlapping arrangement.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring to the drawings, several aspects of the present invention areillustrated by way of example, and not by way of limitation, in detailin the figures, wherein:

FIG. 1 is a perspective, partial cut-away view of most of the componentsof a first embodiment of the insulated modular roof system;

FIG. 2A is a perspective side view of most of the components of theembodiment of the insulated modular roof system of FIG. 1;

FIG. 2B is a sectional side view of a modular panel of the embodiment ofthe insulated modular roof system of FIG. 1;

FIG. 2C is a sectional side view of the modular insulated roof system ofthe embodiment of FIG. 1, illustrating the overlapping area and overlapwidth;

FIGS. 3A and 3B are partially exploded and partially cut-awayperspective views of a modular panel of another embodiment of theinsulated modular roof system of FIG. 1, with the water-proof memberprovided in sections on each modular panel;

FIG. 4 is a perspective view of most of the components of anotherembodiment of the insulated modular roof system, illustrating a slightslope to the overall roof system;

FIG. 5 is a sectional side view of another embodiment of a modularpanel, with the water-proof member provided as a section on each modularpanel, having a second planar member and wherein the thermal break is atube washer; and

FIG. 6 is a sectional side view of yet another embodiment of a modularpanel, with the water-proof member provided as a section on each modularpanel, having a second planar member and wherein the thermal break is abracket depending from the first planar member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is of preferred embodiments by way of exampleonly and without limitation to the combination of features necessary forcarrying the invention into effect. Reference is to be had to theFigures in which identical reference numbers identify similarcomponents. The drawing figures are not necessarily to scale and certainfeatures are shown in schematic or diagrammatic form in the interest ofclarity and conciseness.

A first preferred embodiment of the insulated modular roof system 10 ofthe present invention is shown in FIGS. 1-3B. The system 10 is comprisedof a plurality of modular panels 20 (individually identified as 20A-20G)and a water-proof member 28. The water-proof member 28 may be providedin sections on each modular panel 20 (e.g. as shown in of FIGS. 3A, 3Band 5) or it may be provided separately and placed (or sprayed) over aplurality of adjacent panels 20 (e.g. the embodiment of FIG. 2C). Wheninstalled on a building or roof structure (not shown), a plurality ofmodular panels 20 will preferably be placed, with their lateral edges 20l in a generally overlapping arrangement OA similar to atongue-and-groove joint, so as to substantially cover the desiredsurface area of the roof structure (not shown); e.g. see the arrangementof panels 20A, 20B and 20C in FIG. 1.

FIG. 1 illustrates three modular panels 20 of a preferred embodiment ofthe system 10, labelled individually as 20A, 20B and 20C. Each modularpanel 20 preferably comprises a first planar member 22 overlying aninsulating layer 24, the panel 20 having a plurality of lateral edges 20l. A second planar member 26 is optionally provided to support theinsulating layer 24, the first planar member 22 and the water-proofmember 28 when module 20 is placed on a roof structure; see theembodiment of FIG. 5.

In the embodiment of FIG. 1, first planar member 22 is a substantiallyrectangular planar member, having a length 22 l and a width 22 w.Insulating layer 24 preferably further comprises a first sublayer 24 aand a second sublayer 24 b portion. More preferably, the first andsecond sublayers 24 a, 24 b are also of a planar configuration eachhaving a length 24 al, 24 bl and a width 24 aw, 24 bw of substantiallythe same dimensions as the length 22 l and a width 22 w of the firstplanar member 22. Even more preferably, the first planar member 22 andthe first sublayer 24 a are oriented or positioned within the panel 20so that their lengths 22 l, 24 al and widths 22 w, 24 aw aresubstantially aligned, while the second sublayer 24 b is oriented orpositioned in an offset manner within the panel 20 (as shown in FIGS.1-3B).

Accordingly, this arrangement of the first planar member 22, the firstsublayer 24 a and the second sublayer 24 b provides for adjacent modularpanels 20 to be positioned with their lateral edges 20 l in a generallyoverlapping arrangement OA. In particular, first sublayer 24 a providesa step-like configuration at one lateral edge (e.g. 20 l) comprising alower edge of insulating materials 24 l, while second sublayer 24 bprovides a reverse step-like configuration at the panel's opposing edge(e.g. 20 l′) comprising a top edge of insulating material 24 t see FIG.2B. Top and lower edges of insulating material 24 t, 24 l cooperatetogether to create the overlapping arrangement OA, see FIGS. 2C.Advantageously, overlapping arrangement OA between adjacent modularpanels 20 result in the system 10 having a monolithic type insulationformation from one modular panel (e.g. 20A) to the next panel (e.g.20B).

As mentioned, in some embodiments of the invention a water-proof member28 portion is provided pre-assembled on each panel (see FIGS. 3A, 3B and5). When installed on a building or roof structure, the modular panel 20may be referred to as a roofing panel 20, the first planar member 22 maybe referred to a top planar member 22 and any second planar member 26may be referred to as a bottom planar member 26; with the insulatinglayer 24 being generally sandwiched between the bottom and top planarmembers 22, 24.

The use of “roofing”, “top,” and “bottom” are used herein as respectivereferences to the orientation of the modular panel 20 on a substantiallyflat roofing structure, but there may be uses of the present disclosurewhere the modular panel 20 may be used in different orientations or onother parts of a building, such as in a substantially verticalorientation on the side of a building, used as siding. The term “up” and“down” may be used with respect to the ground. More specifically, theterm “up” may be used to describe a vector that is normal to the groundand away from the ground. More specifically, the term “down” may be usedto describe a vector that is normal to the ground and pointing towardthe ground. A normal is a vector that is perpendicular to a surface suchas the ground surface. In one embodiment, normal may be defined as aconstituent being at +/−90 degrees with respect to a plane. Duringmanufacturing of the modular panel 20, however, the insulating layer 24may be placed or sprayed on the first planar member 22 (said member 22then being a “bottom” planar member during the manufacturing process);the modular panel 20 subsequently flipped over, so that first planarmember 22 generally overlays insulating layer 24 when placed on a roofstructure 24, then being a “top” planar panel.

The first and second planar members 22, 26 may be rigid membersconstructed from oriented strand board (OSB), plywood, gypsum board,cement board or other suitably strong material typically used forsheathing in the roof construction industry. Advantageously, firstplanar member 22 provides additional support and protection to thesystem 10, as compared to U.S. Pat. No. 6,418,687 where a rubbermembrane is simply applied over top of sprayed insulation.

In one embodiment of the insulated modular roof system 10, first planarmember 22 is preferably made up ⅜ inch thick oriented strand board (OSB)sheets, measuring approximately 96 inches×48 inches (8 feet×4 feet) inlength and width. Preferably, insulating layer 24 has a thickness of atleast 2 inches, with top and lower edges 24 t, 24 l of insulating layer24 cooperating together to create an overlapping arrangement OA betweenadjacent modular panels 20. More preferably, the overlapping arrangementOA of this embodiment provides for an overlap width OW of at least 2inches. Advantageously, overlapping arrangement OA provides furtherinsulating and vapour barrier features to the system 10.

Modular panels 20 may be fastened or mounted to a roof structure (notshown) via one or more fasteners 30 driven, mounted or screwed throughfirst planar member 22 and insulating layer 24 (and any second planarmember 26) at a desired position, e.g. as illustrated in FIGS. 1-3.Preferably, a thermal barrier or thermal break 35 is provided to reduceor prevent the flow of thermal energy from the roofing structure (notshown) through the modular panels 20 and out to the environment.

In the embodiments of FIGS. 1-5, the thermal break 35 is a polyamidetube washer having a flanged washer-like top 35 w and a tubular member35 t depending therefrom. A suitable tube washer 35 is the HTK 50™telescopic tube washer manufactured by EJOT UK Ltd of Leeds, UnitedKingdom. The tubular member 35 t is preferably inserted throughappropriately sized and aligned openings 22 o, 24 o in the first planarmember 22 and insulating layer 24, with washer-like top 35 w overlayingthe top of the first planar member 22 (see FIGS. 2B and 5). Fasteners 30can inserted through washer-like top 35 w and then positioned through,and captured by, the tubular member 35 t to then engage the roofingstructure (not shown); see FIGS. 2B and 5. Prior to placement of thewater-proof member 28 over the first planar member 22, tube washer 35and openings 22 o, 24 o may be filled with a spray foam (SF) to furtherreduce or prevent the flow of thermal energy from the roofing structurethrough the fastener 30 (see FIG. 5).

The embodiment of FIG. 6 is similar to the embodiment of FIG. 5, but inthis embodiment the thermal break 35 comprises a bracket member 37mounted to, and depending from, the first planar member 22 into theinsulating layer 24. Bracket member 37 is suitable to capture a screw-or bolt-like fastener, which may be inserted through appropriately sizedand aligned openings 22 o, 24 o in the first planar member 22 andinsulating layer 24. Prior to placement of the water-proof member 28over the first planar member 22, bracket 37 and openings 22 o, 24 o maybe filled with spray foam (SF) to further reduce or prevent the flow ofthermal energy from the roofing structure through the fastener 30.

Advantageously said openings 22 o, 24 o and thermal break 35 provideease of access to an installer to fasten modular panels 20 to a roofstructure (i.e. access from the top of panel 20), while also reducing orpreventing the flow of thermal energy from any underlying roofstructures (as compared to simply driving a fastener through panel fromthe top). Fasteners 30 may be any suitable fastener, e.g. those types offasteners used in the roofing industry to fasten sheathing to a roofingstructure. For example, fasteners 30 may be self-tapping metal screws.Or if using HTK 50™ telescopic tube washers, then fasteners 30 arepreferably the EJOT Dabo™ screw model TKR-4.8™ also manufactured by EJOTUK Ltd of Leeds, United Kingdom. Alternatively, modular panels 20 may bemounted to the roofing structure using a glue or construction adhesive.

As is now understood, the bulk of the insulating properties of thesystem 10 are derived from the insulating layer 24 of the modular panels20. Advantageously, the overlapping area OA significantly reduces onsitelabour, e.g. as compared to cases where spray foam is applied onsite tothe entire roofing surface, or along joints between adjacent panels. Anyspray foam application of the present system 10 is optional and thenonly in any openings 22 o, 24 o and in the thermal breaks 35.

Advantageously, a roof or roofing structure may quickly be covered by aplurality of modular panels 20 arranged in overlapping configuration.More advantageously, by mounting the modular panels 20 to the roofstructure via a tube washer 35 thermal bridge through the first planarmember 22, and by covering the thermal bridge openings 22 o, 24 o withspray foam SF, the amount of heat loss through the system 10 isminimized as compared to cases where a modular panel 20 is mounted to aroof structure via a fastener that penetrates the first planar member22, the insulating layer 24 and any second planar member 24. Instead, inthe embodiment of the present system 10, any thermal bridging that mightotherwise occur across fastener(s) 30 is significantly reduced oreliminated by having the fastener(s) 30 engage the first planar member22 via the thermal breaks 35.

The insulating layer 24 is preferably a polyurethane foam insulationand, more preferably, is a closed cell foam. In other embodiments, theinsulating layer 24 may be comprised of a foamed synthetic resin made ofpolystyrene, polyethylene, acrylic resin, phenol resin, urea resin,epoxy resin, diallylphthalate resin, urethane resin and the like.

Advantageously, the use of closed cell foam insulation in the insulatinglayer 24, along with the overlapping arrangements OA and an overlapwidth of at least 2 inches, provides an air/vapor/water barrier betweenthe modular panel 20 and inherent in system 10, so as to efficientlyinsulate roofs and roofing structures; especially once the panels 20 arefastened to the roofing structure. More advantageously, the resultingsystem 10 will then have a monolithic type insulation formation from onemodular panel (e.g. 20A) to the next panel (e.g. 20B), providing an airtight system 10 and eliminating the need for an external vapor barrier.

The invention thereby provides an insulated modular roofing system 10that can be quickly installed on a roofing structure, with minimalon-site labour, with a desired slope S pre-manufactured in each modularpanel 20 and with a continuous (inherent) vapour barrier across themodular panels 20 on the roofing structure. Advantageously, theinvention may allow for the roofing of a building without the need foradditional vapour control, such as separate polyethylene sheets that aretypically used between a roof deck or roof structure and any overlyinginsulating material.

The thickness of the insulating layer 24 may be determined by theinsulation value that is desired to be achieved by the system 10. Forexample, a 3.33 inch thick insulating layer 24 comprised of 2-poundmedium density, closed-cell polyurethane foam insulation, with the firstand second planar member 22, 26 comprising ⅜ inch thick OSB sheets willtypically provide an insulating value of R-20 to the modular panel 20and the system 10. A 5.83 inch thick insulating layer 24 comprised of2-pound polyurethane foam insulation, with the first and second planarmember 22, 26 comprising ⅜ inch thick OSB sheets will typically providean insulating value of R-35. Advantageously, a closed-cell foam isresistant to water absorption.

During manufacture of the modular panel 20, the insulating layer 24 maybe sprayfoam-applied onto the first planar member 22 and then such sprayfoam insulating layer 24 may cut or shaped to the desired thickness andslope S. This may be accomplished using a horizontal band saw or ahorizontal fastwire foam cutter. The CUTLAS™ horizontal fastwire foamcutter is designed for slicing polyurethane foam into sheets of desiredthickness and would be suitable for this application.

For example, a partially assembled modular panel 20, with a first planarmember 22 measuring 4 feet×8 feet may have the insulating layer 24sprayfoamed thereon to a minimum thickness (e.g. of at least 3.5inches). This partially assembled modular panel 20 can then be movedthrough a CUTLAS™ horizontal fastwire foam cutter which is then set tocut off a thin top section of the spray foamed insulating layer 24 (e.g.to a height of 3.33 inches), thereby providing a smooth top surface,suitable to receive the second planar member. Alternatively, where aroof slope is desired, the CUTLAS™ horizontal fastwire foam cutter canbe adjusted to cut the insulating layer 24 at a pre-set slope, resultingin a modular panel 20 that has that desired slope S with the insulatinglayer 24 having a first thickness (or height) H1 at one end of the panel20 a and a second thickness (or height) H2 at an opposing end 20 b ofthe panel (see the embodiment of FIG. 4).

Advantageously, by having a smoothly cut insulating layer 24, and byutilizing the first planar member 22, the water-proof member 28 onoutside or top surface of the system 10 of modular panels 20 will besubstantially smooth, thereby reducing or fully eliminating ponding orpooling of trapped water or other precipitation in localized areas.Furthermore, if a slight slope S has been provided by the modular panels20, then water or other precipitation will generally be directed toquickly run off of the outside or top surface of the system 10.

The water-proof membrane 28 is preferably an ethylene-propylene dienemar (EPDM) rubber membrane, but it may also be made of other suitablewater-proof roofing material such as a membrane made from a variety ofmaterials such as styrene-butadiene rubber, acrylonitrile-butadienerubber, chloroprene rubber, butadiene rubber, isoprene rubber, butylrubber, ethylene-propylene rubber, polyisobutylene,styrene-butadiene-styrene block copolymer, styrene-isoprene-styreneblock copolymer, chlorinated polyethylene, polyurea coating,ethylene-vinyl acetate copolymer, or SBS modified bitumen roofingmembrane.

In the embodiments where the water-proof membrane 28 is provided insections on each modular panel 20 (e.g. FIGS. 3A, 3B and 5), the lengthand width dimensions of such section 28 s of the water-proof member 28is preferably larger than the length and width of the first planarmember 22, so as to overlap with adjacent sections 28 s once any modularpanels 20 are placed in an overlapping arrangement OA. Advantageously,such overlapping sections 28 s of water-proof member 28 can be taped andsealed (e.g. with seam tape and/or a solvent adhesive), afterinstallation of the modular panels 20, so as to provide an overallwater-proof member 28 to the system 10. For example, an installer canapply 75 mm (3″) wide EPDM seam tape to membrane 28 overlaps using asolvent adhesive.

Those of ordinary skill in the art will appreciate that variousmodifications to the invention as described herein will be possiblewithout falling outside the scope of the invention. In the claims, theword “comprising” is used in its inclusive sense and does not excludeother elements being present. The indefinite article “a” before a claimfeature does not exclude more than one of the features being present.

1. An insulated modular roof system for a roof structure, comprising: aplurality of modular panels suitable for installation onto the roofstructure; and a water-proof membrane, wherein each of said plurality ofmodular panels comprises: a first planar member; an insulating layercovering substantially all of the first planar member; and a pluralityof lateral edges; wherein each one of said plurality of lateral edgesprovides either a step-like configuration or a reverse step-likeconfiguration; and wherein, when installed on the roof structure, theplurality of modular panels are positionable so as to place theplurality of lateral edges of any two adjacent modular panels in agenerally overlapping arrangement.
 2. The insulated modular roof systemof claim 1 wherein the first planar member of each of the plurality ofmodular panels has a length and a width; wherein the insulating layer ofeach of the plurality of modular panels further comprises a firstsublayer and a second sublayer; wherein each of the first and secondsublayers are of a planar configuration; and wherein the first andsecond sublayers each have a length and a width of substantially thesame dimensions as the length and a width of the first planar member. 3.The insulated modular roof system of claim 2 wherein, for each of theplurality of modular panels, the first sublayer is oriented within themodular panel so that the length and width of the first sublayer issubstantially aligned with the length and widths of the first planarmember; wherein, for each of the plurality of modular panels, the secondsublayer is oriented within the modular panel in an offset manner toboth the first planar member and the second sublayer so as to provide astep-like configuration at a first lateral edge of said plurality oflateral edges and a reverse step-like configuration at an opposingsecond lateral edge of said plurality of lateral edges; and wherein thestep-like configuration in one of said plurality of modular panelscooperates with the reverse step-like configuration of an adjacentmodular panel of said plurality of modular panels to form theoverlapping arrangement.
 4. The insulated modular roof system of claim 3wherein the overlapping arrangement provides for an overlap width of 2inches.
 5. The insulated modular roof system of claim 4 wherein, each ofthe plurality of modular panels, further comprises: at least one thermalbarrier suitable to accept a fastener; and at least one opening throughthe planar member, said opening configured to accept said thermalbarrier therethrough.
 6. The insulated modular roof system of claim 4wherein, each of the plurality of modular panels, further comprises: atleast one opening through the planar member, said opening configured toaccept a fastener therethrough; and for each of said at least oneopening, a bracket member depending from the first planar member intothe insulating layer and aligned with said at least one opening; andwherein the bracket member is configured to capture a fastener.
 7. Theinsulated modular roof system of claim 3, wherein the insulating layerof each of said plurality of modular panels has a pre-set slope having afirst thickness at one end of each of said modular panel and a secondthickness at an opposing end of each of said modular panel.
 8. Aninsulated modular roof system for a roof structure comprising: aplurality of modular panels suitable for installation onto the roofstructure; and a water-proof membrane, wherein each of said plurality ofmodular panels comprises: an insulating layer having a plurality oflateral edges; wherein each one of said plurality of lateral edgesprovides either a step-like configuration or a reverse step-likeconfiguration; and wherein, when installed on the roof structure, theplurality of modular panels are positionable so as to place theplurality of lateral edges of any two adjacent modular panels in agenerally overlapping arrangement.
 9. A modular roofing panel suitablefor installation onto a roof structure, the modular roofing panelcomprising: a first planar member; an insulating layer coveringsubstantially all of the first planar member; and a plurality of lateraledges; wherein each one of said plurality of lateral edges provideseither a step-like configuration or a reverse step-like configuration;and wherein, when a plurality of modular panels is installed on the roofstructure, said plurality of modular panels are positionable so as toplace the plurality of lateral edges of any two adjacent modular panelsin a generally overlapping arrangement.
 10. The insulated modular roofsystem of claim 9 wherein the first planar member has a length and awidth; wherein the insulating layer further comprises a first sublayerand a second sublayer; wherein each of the first and second sublayersare of a planar configuration; and wherein the first and secondsublayers each have a length and a width of substantially the samedimensions as the length and a width of the first planar member.
 11. Theinsulated modular roof system of claim 10 wherein the first sublayer isoriented within the modular panel so that the length and width of thefirst sublayer is substantially aligned with the length and width of thefirst planar member; wherein the second sublayer is oriented within themodular panel in an offset manner to both the first planar member andthe second sublayer so as to provide a step-like configuration at afirst lateral edge of said plurality of lateral edges and a reversestep-like configuration at an opposing second lateral edge of saidplurality of lateral edges; and wherein the step-like configuration ofsaid modular panel is suitable to cooperate with a reverse step-likeconfiguration of another adjacent modular panel so as to form theoverlapping arrangement.
 12. The insulated modular roof system of claim11 wherein the overlapping arrangement provides for an overlap width of2 inches.
 13. The insulated modular roof system of claim 12 furthercomprising: at least one thermal barrier suitable to accept a fastener;and at least one opening through the first planar member, said openingconfigured to accept said thermal barrier therethrough.
 14. Theinsulated modular roof system of claim 12 further comprising: at leastone opening through the planar member, said opening configured to accepta fastener therethrough; and for each of said at least one opening, abracket member depending from the first planar member into theinsulating layer and aligned with said at least one opening; and whereinthe bracket member is configured to capture a fastener.
 15. Theinsulated modular roof system of claim 11, wherein the insulating layerof each of said plurality of modular panels has a pre-set slope having afirst thickness at one end of each of said modular panel and a secondthickness at an opposing end of each of said modular panel.
 16. Amodular panel suitable for installation onto the roof structure, themodular panel comprising: a section of water-proof membrane; aninsulating layer having a plurality of lateral edges; wherein each oneof said plurality of lateral edges provides either a step-likeconfiguration or a reverse step-like configuration; and wherein, wheninstalled on the roof structure, the plurality of modular panels arepositionable so as to place the lateral edges of any two adjacentmodular panels in a generally overlapping arrangement.